Introduction Hambro - SwirnowIntroduction Hambro ® COMPOSITE FLOOR SYSTEMS Page 1.00 This manual...

Introduction Hambro®

COMPOSITE FLOOR SYSTEMS

Page 1.00

This manual has beendeveloped in order to assist youin a more completeunderstanding of the Hambro®D-500 and MD-200 FloorSystems, and for you to have atyour fingertips the informationnecessary for the most efficientand economical use of ourHambro® products.

Suggested detailing and designinformation throughout thismanual illustrates methods ofuse. To achieve maximumeconomy and to save valuabletime we suggest that you contactyour local Hambro represent-ative. He is a qualifiedtechnician and is prepared toassist with the selection bestsuited for your particularrequirement.

The contents of this documentare the proprietary trade secretsand confidential information ofSwirnow Structures LLC, andshall not be reproduced in wholeor parts, without prior writtenconsent of Swirnow StructuresLLC.

General Hambro® D-500

Information

Page 1.01

General InformationThe Hambro® D-500 composite floor systemis adaptable to all types of construction i.e.masonry, steel studs, steel frame, poured inplace and precast concrete as well as woodconstruction. Hambro® is well suited for alltypes of applications ranging from singlefamily detached houses to multi-storyresidential and office complexes.

The unique S-shaped top chord section hasfour basic functions:

1. It is the compression member of theHambro® joist during the non-compositeconcreting stage. Remember that thesystem is not propped.

2. It is a “high chair" for the welded wiremesh, developing negative momentcapacity in the concrete slab where it isrequired over the joist top chord.

3. It locks with and supports the slabforming system (Rollbars® and forms.)

4. It automatically becomes a continuous shear connector for the composite stage.

General DescriptionThe Hambro® D-500 Composite Floor Systemessentially consists of a hybrid concrete/steeltee-beam in one direction and an integratedcontinuous one-way slab in the otherdirection and is illustrated in Figs. 1 and 2.

The bottom chord acts as a tension memberduring both the concreting stage and theservice life.

The web system, consisting of bent rods, tiesthe top and bottom chords together andresists the vertical shears in the conventionaltruss manner.

The concrete slab is reinforced with weldedwire mesh at the required locations andbehaves structurally as a continuous one-wayreinforced concrete slab

The rigid plywood sheets and Rollbars®, whenlocked into the S-shaped top chord section,not only act as simple forms for placingconcrete, but provide the essential lateraland torsional stability to the entire Hambro®

Floor System during the concreting stage.

The interaction between the concrete slaband Hambro® joist begins to occur once thewet concrete begins to set. The necessarycomposite interaction for construction loadsis achieved once the concrete strength, f’creaches 500 psi (3.5 MPa). This will usuallyoccur within 24 hours. Even in the coldest ofwinter concrete pouring conditions,construction heating will maintain theconcrete at temperatures necessary for thisstrength gain. When in doubt, concrete testcylinders can be used to verify strength.

General Hambro® D-500

Information

Page 1.02

Advantages

A number of the more important advantagesof Hambro® D-500 Composite Floor Systemare listed below:

• The Hambro® joists are custommanufactured to suit particular jobconditions and are easily erected. It isimportant to remember that the Hambrojoist modular spacing can be adjusted tosuit varying conditions.

• The Hambro® forming system provides a

rigid working platform. Masonry tie beamsor walls may be filled, when required,using the Hambro floor as a working deck.

• Shallower floor depths can be used

because of the increased rigidity of thesystem resulting from the compositeaction, helping to reduce building height.

• The wide Hambro® joist spacing allows

greater flexibility for mechanicalengineers and contractors. Standard pipelengths can be threaded through theHambro® web system. This means fewermechanical joints.

• The ceiling plenum can accommodate

all electrical and mechanical ducting,eliminating the need for bulkheading anddropped ceilings.

• The interlocking of concrete with steel

provides excellent lateral diaphragmaction with the composite joists acting asstiffeners for the entire system.

• Other subtrades can closely follow

Hambro®, thereby shortening completiontime.

• The Rollbars® and plywood sheets are

reusable. Excellent Acoustical Properties: TheHambro® Composite Floor System has asound transmission class (STC) of 57 with theaddition of a gypsum board ceiling.

• Superior Fire Ratings: U.L. designs permit

unprotected penetrations through gypsumboard ceilings, eliminating fire dampersor protection at ceiling openings.

• Slab penetrations are made easy by using

sleeves, styrofoam or wood blocking priorto concreting. Slender 3,000 PSI slabmakes coring simpler, if necessary. Nometal deck to cut or tendons to beconcerned with.

General Hambro® MD-2000

Information

Page 1.03

General InformationThe Hambro® MD-2000 composite floorsystem is adaptable to all types ofconstruction i.e. masonry, steel studs, steelframe, poured in place and precastconcrete as well as wood construction.Hambro® is well suited for all types ofapplications ranging from single familydetached houses to multi-story residentialand office complexes.

The unique S-shaped top chord section hasfour basic functions:

1. It is a compression member componentof the Hambro® non-composite joistduring the concreting stage. Rememberthat the system is not propped.

2. It is a “high chair" for the welded wiremesh, developing negative momentcapacity in the concrete slab where it isrequired over the joist top chord.

3. It supports the slab forming metaldecksystem.

4. It automatically becomes a continuousshear connector for the composite stage.

General DescriptionThe Hambro® MD-2000 Composite FloorSystem essentially consists of a hybridconcrete/steel tee-beam in one direction andan integrated continuous one-way slab in theother direction. and is illustrated in Figs. 1and 2.

FIG. 1

FIG. 2

The bottom chord acts as a tension memberduring both the concreting stage and theservice life.

The web system, consisting of bent rods, tiesthe top and bottom chords together andresists the vertical shears in the conventionaltruss manner.

The concrete slab is reinforced with weldedwire mesh at the required locations andbehaves structurally as a continuous one-wayreinforced concrete slab.

The interaction between the concrete slaband Hambro® joist begins to occur once thewet concrete begins to set. The necessarycomposite interaction for construction loadsis achieved once the concrete strength, f’creaches 500 psi (3.5 MPa). This will usuallyoccur within 24 hours. Even in the coldest ofwinter concrete pouring conditions,construction heating will maintain theconcrete at temperatures necessary for thisstrength gain. When in doubt, concrete testcylinders can be used to verify strength.

General Hambro® MD-2000

Information

Page 1.04

Advantages

A number of the more important advantagesof Hambro® Composite Floor Systems arelisted below:

• The Hambro® joists are custommanufactured to suit particular jobconditions and are easily erected. It isimportant to remember that the Hambrojoist modular spacing can be adjusted tosuit varying conditions.

• The Hambro® metal deck system provides

a rigid working platform. Masonry tiebeams or walls may be filled, whenrequired, using the Hambro floor as aworking deck.

• Shallower floor depths can be used

because of the increased rigidity of thesystem resulting from the compositeaction, helping to reduce building height.

• The wide Hambro® joist spacing allows

greater flexibility for mechanicalengineers and contractors. Standard pipelengths can be threaded through theHambro web system. This means fewermechanical joints and eliminates theneed for bulkheads and drop ceilings.

• The ceiling plenum can accommodate

all electrical and mechanical ducting,eliminating the need for bulkheading anddropped ceilings.

• The interlocking of concrete with steel

provides excellent lateral diaphragmaction with the composite joists acting asstiffeners for the entire system.

• Other subtrades can closely follow

Hambro®, thereby shortening completiontime.

• Excellent Acoustical Properties: The

Hambro® Composite Floor Systems have asound transmission class (STC) of 57 withthe addition of a gypsum board ceiling.

• Superior Fire Ratings: U.L. designs permitunprotected penetrations through gypsumboard ceilings, eliminating fire dampersor protection at ceiling openings.

Hambro® D-500

Specifications

Page 2.00

PART I GENERAL

1-1 SCOPE:The Contractor shall:

(a) Furnish all labor, materials, equipment,supervision and services necessary forand incidental to the fabrication andinstallation of the Hambro® CompositeFloor System in accordance with thesespecifications and applicable drawings.Hambro® Steel joists, and Rollbars®,marketed by authorized representatives.

(b) Fully coordinate the Hambro® joists withthe other structural, mechanical, electricaland architectural components of thebuilding.

PART 2 TYPICAL SPECIFICATION

2-1 CODES:All fabrication shall be in strict accordance withthe Hambro® Shop Standard Practice, usingsteel conforming to ASTM Standards.Structural, fire and sound characteristics shallmeet the requirements of the Building Officialsand Code Administrators International, Inc.(BOCA), the International Conference ofBuilding Officials (ICBO), the Southern BuildingCode Congress (SBCC), and the United StatesDepartment of Housing and UrbanDevelopment, Federal Housing Administration(HUD/FHA), South Florida Building Code (asapplicable).

2-2 DESIGN:Flexural design shall be by the UltimateStrength method and as described in theHambro® literature. The slab shall be designedin accordance with the Building CodeRequirements for Reinforced Concrete (ACI318-71); the top chord shall be designed inaccordance with the American Iron and SteelInstitute Specification for the Design ofCold-Formed Steel Structural Members; andthe webs shall be designed for loading inaccordance with the Steel Joist Institute.

2-3 QUALIFICATIONS

(a) All welding materials and methods used forfabrication shall be in accordance with therequirements of the Hambro® Shop StandardPractice

(b) All field welders shall be certified,qualified operators for the materials andmethods being used, except thatHambro® joist repairs or modificationsthat may be required may be done byfactory approved personnel.

2-4 DRAWINGS:(a) Submit detailed shop drawings to the

General Contractor for approval showingmaterial lists, types, Iocations, loadingsand spacing of all joists andaccessories. Contract drawing notesrelative to the Hambro® System shall beconsidered a part of this specification asthough fully set forth herein.

(b) Shop tickets prepared only fromcustomer approved Field Use shopdrawings shall be used for fabrication.

(c) Figured dimensions only shall be used;scaling drawings shall not be permitted.

2-5 HANDLING AND STORAGE:Care shall be exercised at all times to avoiddamage to Hambro® joists through carelesshandling during unloading storing anderecting.

PART 3 PRODUCTS

3-1 MATERIALS:(a) Hambro® joists.

(1) All composite joists shall be fabricatedby Canam Hambro® in accordance withSection 2.1 and 3.1 of theseSpecifications.

(2) Top chord member shall act as acontinuous shear connector of coldrolled steel minimum 13 gauge with Fy= 50,000 p.s.i. minimum

(3) Bottom chord member shall consist ofeither hot or cold rolled angles with Fy= 50,000 p.s.i. minimum.

4) Web members designed to equal orexceed Steel Joist Institute (SJI)specifications shall consist ofminimum 7/16 diameter hot rolledbars, some of which are continuous,bent at top chord joist locations withFy = 44,000 p.s.i. minimum.

(5) All composite joists shall be shop paintedwith a rust inhibitive primer.

Hambro® D-500

Specifications

Page 2.01

(b) Rollbars® shall be designed specifically tosupport 3/8” or 1/2” plywood forms, 40 psfconstruction load and slab weight until thestab has cures sufficiently (concrete cylinderstrength of 500 p.s.i.). and act as temporarybridging and spacers for Hambro compositejoists.

(c) Standard bearing shoes shall be angle shape4” x 1-3/4” x , x 5” wide unless otherwisenoted.

(d) Slab reinforcement shall be minimum 6 x 6W2.0 x W2.0 welded wire fabric. with Fy =60,000 p.s.i. minimum unless otherwiserequired by structural engineer.

(e) Forms shall be 4’ or 5’ plywood sheets andmay be 3/8" or 1/2" thick.

(f) Concrete(1) Minimum ultimate compressive strength f

c = 3.000 p.s.i. at 28 days(2) Standard weight i.e. 145 psf(3) Maximum size coarse aggregate: 3/4'"

3-2 FABRICATION(a) Fabrication shall be in accordance with the

Hambro® Shop Standard Practice.(b) The joist top chord shall be fabricated to allow

for 1-1/2" embedment into the concrete slab.(c) After installation permissible Hambro® joist

sweep shall be 1” in 20’(d) Hambro® joists shall be fabricated with

approximately the following cambers:10-20 span ................................. 0 to 1/2”20-30 span ............................. 1/2” to 3/4"30-40 span ................................ 3/4" to 1”

QUALITY CONTROL:Joist shall be manufactured in a fabricator’s facilityhaving a continuous quality control program andsubjected to plant inspections by an approvedindependent agency. The inspection shall includechecking of size, span, assembly and weld.

PART 4 EXECUTION4-1 ERECTION:(a) Installation of the Hambro® D-500composite floor system shall be in accordance withthe latest erection manual, approved shop drawingsand any amendments which may be issued by themanufacturer.

(b) All joists shall be erected in such a mannerso that they are vertical level and plumb andat the proper elevations. Any shimming thatmay be required shall be done with metal.

(c) Special conditions requiring top and/orbottom bracing shall be shown on shopdrawings prepared by supplier.

(d) Welded Wire Fabric lapping shall be inaccordance with the provisions of ACI 318

(e) End anchorage - joist shoes shall be properlyanchored or embedded as per engineer's orarchitect's drawings.

(f) Concreting Practice(1) Do not pour concrete in excess of the slab

thickness stated on the shop drawings.(2) Do not drop large bucket loads in con-

centrated areas over Hambro joists. Lightlyvibrate concrete.

(3) Construction joints made parallel to thejoists should be made midway between thejoists but never closer than 6" to the topchord. Construction joints madeperpendicular to the joists should belocated over the supporting wall or beam.

(4) It is recommended that the following ACIpublications be followed:(a) ACI 301 - Specifications for Structural

Concrete for Buildings.(b) ACI 305 - Recommended Practice for

Hot-Weather Concreting.(c) ACi 306 - Recommended Practice for

Cold-Weather Concreting.(g) Stripping D-500: Under normal conditions

form-work may be stripped at such time as theconcrete has reached a cylinder strength of500 p.s.i.

(h) Construction Loads(1) Bundles of plywood or Rollbars® should

not be placed on joist system but ratheron supporting walls or beams.

(2) The joists are designed to resist thecombined weight of the wet concrete(specified slab thickness), formwork,Rollbars®, and a construction load of 20PSF maximum.

(I) Minimum joist bearing shall be as follows:(1)Steel support: 2_”

(2) Masonry, concrete and wood support: 3_”bearing capacity of supporting units to comply withapplied shoe end reaction, based on minimumsupplied bearing of 17.5 square inches.

Hambro® MD-2000

Specifications

Page 2.02

PART I GENERAL

1-1 SCOPE:The Contractor shall:

(a) Furnish all labor, materials, equipment,supervision and services necessary forand incidental to the fabrication andinstallation of the Hambro® CompositeFloor System in accordance with thesespecifications and applicable drawings.Hambro® Steel joists and metal deck shallbe manufactured and marketed by CanamHambro® or their authorizedrepresentatives.

(b) Fully coordinate the Hambro® joists withthe other structural mechanical electricaland architectural components of thebuilding.

PART 2 TYPICAL SPECIFICATION

2-1 CODES:All fabrication shall be in strict accordance withthe Hambro® Shop Standard Practice, usingsteel conforming to ASTM Standards.Structural, fire and sound characteristics shallmeet the requirements of the Building Officialsand Code Administrators International Inc.(BOCA), the International Conference ofBuilding Officials (ICBO), the Southern BuildingCode Congress (SBCC), and the United StatesDepartment of Housing and UrbanDevelopment, Federal Housing Administration(HUD/FHA), South Florida Building Code (asapplicable).

2-2 DESIGN:Flexural design shall be by the UltimateStrength method and as described in theHambro® literature. The slab shall be designedin accordance with the Building CodeRequirements for Reinforced Concrete (ACI318-71); the top chord shall be designed inaccordance with the American Iron and SteelInstitute Specification for the Design ofCold-Formed Steel Structural Members; andthe webs shall be designed for loading inaccordance with the Steel Joist Institute.

2-3 QUALIFICATIONS

(a) All welding materials and methods used forfabrication shall be in accordance with therequirements of the Hambro® Shop StandardPractice

(b) All field welders shall be certified,qualified operators for the materials andmethods being used, except thatHambro® joist repairs or modificationsthat may be required may be done byfactory approved personnel.

2-4 DRAWINGS:(a) Submit detailed shop drawings to the

General Contractor for approval showingmaterial lists, mark numbers, types,Iocations, loadings and spacing of alljoists and accessories. Contract drawingnotes relative to the Hambro® Systemshall be considered a part of thisspecification as though fully set forthherein.

(b) Shop tickets prepared only fromcustomer Approved/Field-Use shopdrawings shall be used for fabrication.

(c) Figured dimensions only shall be used;scaling drawings shall not be permitted.

2-5 HANDLING AND STORAGE:Care shall be exercised at all times to avoiddamage to Hambro® joists through carelesshandling during unloading storing anderecting.

PART 3 PRODUCTS

3-1 MATERIALS:(a) Hambro® joists.

(1) All composite joists shall be fabricatedby Canam Hambro® in accordance withSection 2.1 and 2.2 of theseSpecifications.

(2) Top chord member shall act as acontinuous shear connector of coldrolled steel, minimum 13 gauge with Fy= 50,000 p.s.i. minimum

(3) Bottom chord member shall consist ofeither hot or cold rolled angles with Fy= 50,000 p.s.i. minimum.

(4) Web members designed to equal orexceed Steel Joist Institute (SJI)specifications shall consist ofminimum 7/16 diameter hot rolledbars, some of which are continuous,bent at top chord joist locations withFy = 44,000 p.s.i. minimum.

Standard bearing shoes shall be angle shape 4” x 1-3/4” x _” x 5” wide unless otherwise noted.

Hambro® MD-2000

Specifications

Page 2.03

(6) All composite joists shall be shop primerpainted with a rust inhibitive primer.

(b) Metal deck shall be 1-1/2” (min 9/16”) deep,24 gauge (min 28ga), type B, uncoated, lightzinc or galvanized metal form deck. Metaldeck shall be fastened or welded to Hambro®

joist deck support angles every 18” (max 24”)along S-shaped top chord.

(c) Slab reinforcement shall be minimum 6 x 6W2.0 x W2.0 welded wire fabric. with Fy =60,000 p.s.i. minimum unless otherwiserequired by structural engineer.

(d) Concrete(1) Minimum ultimate compressive strength

f c = 3.000 p.s.i. at 28 days(2) Standard weight i.e. 145 psf(3) Maximum size coarse aggregate: 3/4”

3-2 FABRICATION(a) Fabrication shall be in accordance with the

Hambro® Shop Standard Practice.(b) The joist top chord shall be fabricated to allow

for 1_" embedment into the concrete slab.(c) After installation permissible Hambro joist

sweep shall be 1” in 20’(d) Hambro® joists shall be fabricated with

approximately the following cambers:10-20 span ................................. 0 to 1/2”20-30 span ..............................1/2” to 3/4"30-40 span ................................ 3/4" to 1”

QUALITY CONTROL:Joist shall be manufactured in a fabricator’s facilityhaving a continuous quality control program andsubjected to plant inspections by an approvedindependent agency. The inspection shall includechecking of size, span, assembly and welds.

PART 4 EXECUTION4-1 ERECTION:

(a) Installation of the Hambro® MD-2000 composite floor system shall be inaccordance with the latest erection manual,approved shop drawings and anyamendments which may be issued by themanufacturer.

(b) All joists shall be erected in such a mannerso that they are vertical, level and plumb and at theproper elevations. Any shimming that may berequired shall be done with metal.

(c) Special conditions requiring top and/orbottom bracing shall be shown on shopdrawings prepared by supplier.

(d) Welded Wire Fabric Lapping shall be inaccordance with the provisions of ACI 318

(e) End anchorage - joist shoes shall be properlyanchored or embedded as per engineer's orarchitect's drawings.

(f) Concreting Practice(1) Do not pour concrete in excess of the slab

thickness stated on the shop drawings.(2) Do not drop large bucket loads in con-

centrated areas over Hambro® joists.Lightly vibrate concrete.

(3) Construction joints made parallel to thejoists should be made midway between thejoists but never closer than 6" to the topchord. Construction joints madeperpendicular to the joists should belocated over the supporting wall or beam.

(4) It is recommended that the following ACIpublications be followed:(a) ACI 301 - Specifications for Structural

Concrete for Buildings.(b) ACI 305 - Recommended Practice for

Hot-Weather Concreting.(c) ACI 306 - Recommended Practice for

Cold-Weather Concreting. (g) Construction Loads

(1) Bundles of metal deck should not beplaced on joist system but rather onsupporting walls or beams.

(2) The joists are designed to resist thecombined weight of the wet concrete(specified slab thickness), metal deck anda construction load of 20 PSF maximum.

(h) Minimum joist bearing shall be as follows:(1)Steel support: 2_”(2)Masonry, concrete and wood support: 3-

1/2” bearing capacity of supporting units tocomply with applied shoe end reaction,based on minimum supplied bearing of17.5 square inches.

Load Tables Hambro®

Hambro mini-joist series COMPOSITE FLOOR SYSTEMS

Page 9.01

Supporting Mechanical Loads from Hambro Joists

Pipe Hangers and Mechanical Loads : Hanger loads of up to 50# can be supported from the slabprovided that the hangers are at least 2’ apart. Hangers in the slab shall be placed within a

zone 6” to 12” of the joists.

Hanger loads above 50# and up to 200# can be hung from the slots in the joist top chord atany location provided that the cumulative mechanical loads do not infringe on the

other design loads. The capacity available to support mechanical loads will vary dependingon joist span and the design loads specified on the plans.

Hangers can also be supported from the joist bottom chords using threaded rods or bolts placed between the bottom chord angles. Hangers from the bottom chords must be placed immediately adjacent to the panel points, (where the web connects to the chord). Do not weld or drill into the Hambro joists.

We have not addressed the type of hangers or anchors that will be used and this should beexamined by the structural engineer, architect, and mechanical engineer. Please makecertain that a proper hanger design is used to eliminate any impact vibration in the slab.

If you have any questions, please call.

Fire Ratings Hambro®


Page FR-01

There are many accepted methods to achieve satisfactory fire protection of the Hambro®

System.

Fire Protective ceiling membranes installed directly under the exposed steel are generally used inresidential construction. They are economical, aesthetically pleasing and can safelyaccommodate residential type lighting fixtures and ventilating units without impairing their firerating capabilities.

Accessible ceiling panels commonly referred to as "lay-in" ceiling tiles are generally used inoffice, commercial and institutional type construction. These removable panels allow access tothe ceiling plenum for alterations to mechanical or electrical equipment.

Insulating the Hambro® joist by sprayed on fireproofing is another accepted method of fireprotection.

The Hambro® Floor System has been fire tested using all types of fire protection and thefollowing is a list of Underwriters Laboratories, Inc., designs that incorporate the Hambro®

products. The latest listings published should be referred to when detailing the fire resistiveassembles.

Design No.

Rating (hr)

SlabThickness (in)

Ceiling (in)gypsum

BeamRating (hr)

G531* 1-1/2 2-1/2 1/2 22 2-3/4 1/2 2

G525 3 3-1/4 5/8 3G524 2 2-1/2 1/2 2

3 3-1/2 1/2 2Suspended Panel

G236 2 2-1/2 “ --G229 2 3 “ 2

3 4 “ 3G228 2 3-1/4 “ 2G227 2 2-1/2 “ 3G213 2 3 “ 3

3 4 “ 3G003 2 2-1/2 “ --

Spray OnG702 1-2-3 Varies “ --G802 “ “ “ --G803 “ “ “ --

*In accordance with U.L. Designs as noted up to 256 sq. in. ceiling penetrations per 100 sq. ft. ofceiling area are approved without the need for fire dampers for 1 hr. rating (196 sq. in. per 100sq. ft. for 1-1/2 hrs. and 100 sq. in. per 100 sq. ft. for 2 hrs.) Check your U.L. Directory forcomplete details or contact your Hambro® representative.



Page FR-02

Summary of the Fire Resistance Rating UL Design No. G531ONE HOUR Assembly.

SUMMARY ON THE HAMBRO® D500, D510 AND MD2000 COMPOSITE FLOOR SYSTEMS

1 . CONCRETE - 2-1/2” minimum slab thickness for the D500 and D510, a 2-3/4” minimum slabthickness for the MD2000, 3,000 PSI minimum strength, 3/4” maximum aggregate size andnormal weight.

2. JOISTS - 8” minimum joist depth or space between bottom of concrete slab and top of furringchannel, if RTC or no joist is present.

3. TIE WIRE - No. 18, galvanized steel wire.4. FURRING CHANNEL - 7/8” high, 2-5/8” wide at base, minimum 25 gauge. Spacing 16” on

center.5. WALLBOARD GYPSUM - 1/2” or 5/8“. Type C, UL listed manufacturers as indicated in UL

directory.6. DRYWALL SCREWS - Type S - 1-1/4” long, 12“ on center.7. JOINT SYSTEM - Paper tape embedded in joint compound over joints and covered with two

layers of joint compound. Wall board screw heads covered with two layers of joint compound.No wallboard end joint protection required.

8. AIR DUCT - Maximum 16” by 16” or 256 square inches of supply or return HVAC unprotectedduct opening per 100 square feet of ceiling area. Flexible air duct up to a nominal 10”diameter and rigid fiberglass air duct allowed for supply of duct openings.

9. HVAC AIR HANDLER - Damper is required between HVAC air handler and plenum if thepenetration exceeds 256 square inches per 100 square feet of ceiling area. The rating alsorequires that air movement is effectively stopped at start of fire, even if the penetration doesnot exceed air duct maximums.

10. EXHAUST DUCT - 6” diameter aluminum duct for exhaust air movement allowed in ratedassembly.

11. RECESSED VENTILATION FAN - 12” x 14” opening with rigid exhaust metal duct.12. RECESSED LIGHTS – As an alternate to the unprotected opening, four lights per 100 square

feet of ceiling area with a direct maximum penetration of 6-3/4” diameter per light (alternateto unprotected duct opening).

13. WALL PARTITIONS - No protection required at the penetration of the top plates in a non-ratedmetal or wood stud partitions.

14. STRUCTURAL STEEL - No protection required if located in the rated assembly.15. MISCELLANEOUS - Materials allowed in rated assembly or in the penetration of the top plate,

6” of a maximum width non-rated partition:A. PVC Pipe - Maximum four in. diameter.B. ELECTRICAL NON-METALLIC TUBING (ENT-PVC) AND ELECTRICAL METALLIC

TUBING.C. ROMEX Type NM Cable and LOW VOLTAGE WIRE (TV, Telephone, Alarm).D. HVAC insulated copper and pvc lines.

Note: The above information has been summarized from the most recent UL Fire ResistanceDirectory, subsequent tests conducted and published reports by UL. Please refer to the UL Directoryfor more detailed information.



Page FR-03

Summary of the Fire Resistance Rating UL Design No. G531ONE AND ONE HALF HOUR Assembly.

SUMMARY ON THE HAMBRO® D500, D510 AND MD2000 COMPOSITE FLOOR SYSTEMS

1 . CONCRETE - 2_ in. minimum slab thickness for the D500 and D510, a 2_ in. minimum slabthickness for the MD2000, 3,000 PSI minimum strength, _ in. maximum aggregate size andnormal weight.

2. JOISTS - 8 in. minimum joist depth or space between bottom of concrete slab and top offurring channel, if RTC or no joist is present.

3. TIE WIRE - No. 18, galvanized steel wire.4. FURRING CHANNEL - 7/8 in. high, 2 5/8 in. wide at base, minimum 25 gauge. Spacing 16 in.

on center.5. WALLBOARD GYPSUM - 1/2 in. or 5/8 in. Type C, UL listed manufacturers as indicated in UL

directory.6. DRYWALL SCREWS - Type S - 1 _ in. long, 12 in. on center.7. JOINT SYSTEM - Paper tape embedded in joint compound over joints and covered with two


8. AIR DUCT - Maximum 14 in. by 14 in. or 196 square in. of supply or return HVAC unprotectedduct opening per 100 square ft. of ceiling area. Flexible air duct up to a nominal 10 in.diameter and rigid fiberglass air duct allowed for supply of duct openings.

9. HVAC AIR HANDLER - Damper is required between HVAC air handler and plenum (minimumtwo hour rating) if the penetration exceeds 196 square in. per 100 square ft. of ceiling area.The rating also requires that air movement is effectively stopped at start of fire, even if thepenetration does not exceed air duct maximums.

10. EXHAUST DUCT – 6 in. diameter aluminum duct for exhaust air movement allowed in ratedassembly.

11. RECESSED VENTILATION FAN - 12 in. x 14 in. opening with rigid exhaust metal duct.12. RECESSED LIGHTS – As an alternate to the unprotected opening, four lights per 100 square

feet of ceiling area with a direct maximum penetration of 6-3/4” diameter per light (alternateto unprotected duct opening).

13. WALL PARTITIONS - No protection required at the penetration of the top plates in a non-ratedmetal or wood stud partitions.

14. STRUCTURAL STEEL - No protection required if located in the rated assembly.15. MISCELLANEOUS - Materials allowed in rated assembly or in the penetration of the top plate,

6 in. maximum width of a non-rated partition:A. ELECTRICAL NON-METALLIC TUBING (ENT-PVC) AND ELECTRICAL METALLIC

TUBING.B. ROMEX Type NM Cable and LOW VOLTAGE WIRE (TV, Telephone, Alarm).

Note: The above information has been summarized from the most recent UL FireResistance Directory, subsequent tests conducted and published reports by UL. Please referto the UL Directory for more detailed information.



Page FR-04

Summary of the Fire Resistance Rating UL Design No. G531TWO HOUR Assembly.

SUMMARY ON THE HAMBRO® D500, AND MD2000 COMPOSITE FLOOR SYSTEMS

1 . CONCRETE – 2 _ in. minimum slab thickness, 3,000 PSI minimum strength, _ in. maximumaggregate size and normal weight.




directory.6. DRYWALL SCREWS - Type S - 1 _ in. long, 12 in. on center.7. JOINT SYSTEM - Paper tape embedded in joint compound over joints and covered with two


8. AIR DUCT - Maximum 10 in. by 10 in. or 100 square in. of supply or return HVAC unprotectedduct opening per 100 square ft. of ceiling area. Flexible air duct up to a nominal 10 in.diameter and rigid fiberglass air duct allowed for supply of duct openings.

9. HVAC AIR HANDLER - Damper is required between HVAC air handler and plenum (minimumtwo hour rating) if the penetration exceeds 100 square in. per 100 square ft. of ceiling area.The rating also requires that air movement is effectively stopped at start of fire, even if thepenetration does not exceed air duct maximums.

10. EXHAUST DUCT - 6 in. diameter Aluminum duct for exhaust air movement allowed in ratedassembly.

11. RECESSED VENTILATION FAN - 12 in. x 14 in. opening with rigid exhaust metal duct.12. RECESSED LIGHTS - One light per 100 square ft. of ceiling area with a maximum penetration

of 7 3/4 in. diameter per light.13. WALL PARTITIONS - No protection required at the penetration of the top plates in a non-rated

metal or wood stud partitions up to 6 in. wide nominal dimension.14. STRUCTURAL STEEL - No protection required if located in the rated assembly.15. MISCELLANEOUS - Materials allowed in rated assembly or in the penetration of the top plate,

6 in. maximum width of a non-rated partition:A. ELECTRICAL NON-METALLIC TUBING (ENT-PVC) AND ELECTRICAL METALLIC

TUBING.B. ROMEX Type NM Cable and LOW VOLTAGE WIRE (TV, Telephone, Alarm).




Page FR-05

Summary of the Fire Resistance Rating UL Design No. G524THREE HOUR Assembly.

SUMMARY ON THE HAMBRO® D500, AND MD2000 COMPOSITE FLOOR SYSTEMS

1 . CONCRETE – 3 _ in. minimum slab thickness, 3,000 PSI minimum strength, _ in. maximumaggregate size and normal weight.




directory.6. DRYWALL SCREWS - Type S - 1 in. long, 12 in. on center.7. JOINT SYSTEM - Paper tape embedded in joint compound over joints and covered with two


8. AIR DUCT - Maximum 113 square in. per 100 square ft. and must be protected with damper.Duct made of 24 gauge galvanized steel.

9. STRUCTURAL STEEL - No protection required if located in the rated assembly.




Page FR-06

SPRAY ON FIREPROOFINGSummary of Fire Resistance Rating UL Design No. G702

ONE, TWO, OR THREE HOUR Restrained and Unrestrained Assembly

SUMMARY ON THE HAMBRO® D500, D510, MD2000 COMPOSITE FLOOR SYSTEM

1. CONCRETE - 3 in. minimum slab thickness for HAMBRO® spaced 50 _ in. o.c. maximum, 4 _ in.minimum slab thickness for HAMBRO® spaced 66 in. o.c. maximum, 3,000 PSI minimum strength,normal weight (150 PCF unit wgt), or structural light weight (117 PCF unit wgt).

a. Concrete slabs are used without protection if the following is met:

Normal Weight Light Weight Concrete Slab in Inches Concrete Slab in InchesJoist Spacing Joist Spacing Min Concrete

Restrained or Cover for WireUnrestrained 50 _ in. 66 in. 50 _ in. 66 in. Fabric FromAssembly o.c. max. o.c. max. o.c. max. o.c. max. Bottom of Slab

In1 Hour 3-3/4 4-1/2 3 4-1/2 11-1/2 Hour 4-1/2 4-1/2 3-1/2 4-1/2 1-1/82 Hour 5-1/4 5-1/4 4 4-1/2 1-1/4

b. Required minimum thickness if underside of concrete slab is to be protected:

Concrete Type One Hour Two Hour Three Hour Restrained Restrained RestrainedNormal Weight 3/8 inch 3/4 inch 1-1/4 inchLight Weight N.A. 3/8 inch 1 inch

2. CEMENTITIOUS MIXTURES - Monokote, Type MK-6

3. JOIST COVERAGE - Required minimum thickness on HAMBRO®

Note: R = Restrained Assembly; U = Unrestrained Assembly

Min Area of Min Area of Thickness ofHourly Rating Joist Bottom Chord Web Sprayed Fiber (square inch) (square inch) (inch) 3 Hour or Less (R) .708 .442 1-1/21-1/2 Hour or Less (U) .708 .442 1-1/22 Hour or Less (R & U) .560 .299 2 w/lath, 2-1/2 wo/lath

4. LATH - (Optional)a. Metal Lath - Diamond mesh, 3/8 in. expanded steel lath, 1.7 to 3.4 lb/sq yard, secured to one sideof each HAMBRO® joist with No. 18 SWG galvanized steel wire at joist web and bottom chord members,spaced 15 inches o.c. maximum. The metal lath is to be fully covered with cementitious mixture with nominimum thickness requirements.

b. Non-metallic Fabric Mesh - Glass fiber fabric mesh, weighing approx. 2.5 oz/sq yard, polypropylene fabricmesh weighing approx. 1.25 oz/sq yard, or equivalent is secured to one side of each HAMBRO® web member.The method of attaching the mesh must be sufficient to hold the mesh and the spray-applied cementitiousmixture material in place during application and until it has cured. An acceptable method to attach the mesh isby embedding the mesh in minimum _ in. long beads of hot-melted glue. The beads of glue shall be spaced amaximum of 12 in. o.c. along the top chord of the HAMBRO® joist. Another method to secure the mesh is by I_in. long by _ in. wide hairpin clips formed from No. 18 SWG or heavier steel wire.



Page FR-07







Restrained or Cover for WireUnrestrained 50 _ in. 66 in. 50 _ in. 66 in. Fabric FromAssembly o.c. max. o.c. max. o.c. max. o.c. max. Bottom of Slab

In1 Hour 3-3/4 4-1/2 3 4-1/2 11 _ Hour 4-1/2 4-1/2 3-1/2 4-1/2 1-1/82 Hour 5-1/4 5-1/4 4 4-1/2 1-1/4

b. The sprayed fiber shall extend three inches onto the bottom of the exposed slab beyond the sides ofthe joist web.

c. Required minimum thickness if underside of concrete slab is to be protected:


2. SPRAYED FIBER - Isolatek International Corporation - Type D-C/F or Type R



Min Area of Min Area of Thickness ofHourly Rating Joist Bottom Chord Web Sprayed Fiber (square inch) (square inch) (inch) 3 Hour or Less (R) .594 .277 2-1/21 1/2 Hour or Less (U) .594 .277 22 Hour or Less (R & U) .443 .222 1-1/2

4. LATH - (Optional)a. Metal Lath - Diamond mesh, 3/8 in. expanded steel lath, 1.7 to 3.4 lb/sq yard, secured to one sideof each HAMBRO® joist with No. 18 SWG galvanized steel wire at joist web and bottom chord members,spaced 15 inches o.c. maximum.

b. Non-metallic Fabric Mesh - Glass fiber fabric mesh, weighing approx. 2.5 oz/sq yard, secured to oneside of each HAMBRO® joist. The method of attaching the mesh must be sufficient to hold the meshand the spray-applied spray-fiber material in place during application and until it has cured. Anacceptable method to attach the mesh is by embedding the mesh in minimum _ in. long beads of hot-melted glue. The beads of glue shall be spaced a maximum of 12 in. o.c. along the top chord of theHAMBRO® joist.



Page FR-08







Restrained or Cover for WireUnrestrained 50 _ in. 66 in. 50 _ in. 66 in. Fabric FromAssembly o.c. max. o.c. max. o.c. max. o.c. max. Bottom of Slab1 Hour 3-3/4 4-1/2 3 4-1/2 11-1/2 Hour 4-1/2 4-1/2 3-1/2 4 -1/2 1-1/82 Hour 5-1/4 5-1/4 4 4-1/2 1-1/4

b. The sprayed fiber shall extend three inches onto the bottom of the exposed slab beyond the sides ofthe joist web.

c. Required minimum thickness if underside of concrete slab is to be protected:


2. SPRAYED FIBER - American Energy Products Corp. - Type standard in fiber, Type A adhesiveoptional. Type TC-SS sealer optional.



Min Area of Min Area of Thickness ofHourly Rating Joist Bottom Chord Web Sprayed Fiber (square inch) (square inch) (inch) 3 Hour or Less (R) .594 .277 2-3/41 1/2 Hour or Less (U) .594 .277 2-3/42 Hour or Less (R & U) .443 .222 1-5/8

4. LATH - (Optional)a. Metal Lath - Diamond mesh, 3/8 in. expanded steel lath, 1.7 to 3.4 lb/sq yard, secured to one sideof each HAMBRO® joist with No. 18 SWG galvanized steel wire at joist web and bottom chord members,spaced 15 inches o.c. maximum.

b. Non-metallic Fabric Mesh - Glass fiber fabric mesh, 3/32 to 3/26 weighing approx. 1.9 to 2.5 oz/sq yardfiberglass scrim fabric, secured to one side of each HAMBRO® web member. The method of attaching the meshmust be sufficient to hold the mesh and the spray-applied spray-fiber material in place during application anduntil it has cured. An acceptable method to attach the mesh is by embedding the mesh in minimum _ in. longbeads of hot-melted glue. The beads of glue shall be spaced a maximum of 12 in. o.c. along the top chord ofthe HAMBRO® joist.

TABLE OF CONTENTS

I. INTRODUCTION Page 1

II. UNLOADING, STORING, AND HANDLING Page 1

III. SETTING THE JOISTS Page 2

IV. INSTALLING THE ROLLBARS® Page 3

V. PLACING THE REMOVABLE PLYWOOD FORMS Page 5

VI. PLACING THE MESH Page 6

VII. PLACING THE CONCRETE Page 7

VIII. STRIPPING THE FORMS Page 8

IX. IMPORTANT NOTICES Page 8

X. WINTER CONSTRUCTION Page 9

XI. MANUFACTURER'S SPECIFICATIONS FORCORRECTIVE REMEDIES IN THE FIELD Page 9

Important Note:

This manual is provided as a basic guide of recommendedtechniques for the installation of the Hambro® Composite FloorSystem. It is not intended to take the place of the requirements ofapplicable building codes. All work must be in accordance with theContract Documents and Approved Shop Drawings for the specificproject. Accordingly, while these guidelines are intended asrecommended general techniques to be followed, these techniquescan be used only to the extent they do not conflict with building coderequirements, construction documents and site conditions. You arerequested to contact your Hambro® Supplier for conditions not clearlycovered in this manual.

Shop Drawings are provided by your Hambro® Supplier for reviewand approval by Purchaser, the Architect, and Engineer of Record toverify and coordinate the joist locations, spans, capacities, loads,details, and to check for correctness in relation to project plans andspecifications. Shop Drawings are based on the latest informationprovided to Supplier which may differ from the contract documents.Hambro® Joists are fabricated only in accordance with the ApprovedShop Drawings. Shop Drawings must always be used in conjunctionwith the construction documents.

I. INTRODUCTION

Take sufficient time to understand the Hambro® System.

The Training Period: Set up a sample training area in the field. Simply take two joists, set them onfour block piles, 4'-1 1/4" apart. Place five or six Rollbars® into position.

Have your workmen stand between the two Hambro® joists, continuously inserting and removing theRollbars® for ten minutes. This time invested will bring you big dividends.

The Hambro® installation ready for concrete breaks down into four simple tasks:1. Setting the joists.2. Setting the Rollbars®.

3. Setting the plywood forms.4. Setting the mesh.

Tools: There are few tools needed to install Hambro®, but trying to skimp on what is needed will costyou in lost production. Be sure to have enough of the proper equipment to keep all men working.

Plan on having the following items available:1. Large hammer and 2" x 4" for tapping joist shoes for proper bearing, and the forms under the

joist seats and beam flanges, if applicable.2. Circular saw, crowbar, hammers.3. Minimum two 2'x6' long rolling scaffolds for Rollbar® installation.4. 4' pipe for levering tight Rollbars® in and out.5. Pallet jack, for large floor areas for movement of pallets of Rollbars® and plywood.6. Form oil and applicator, optional. (Do not spray the joists or mesh.)

II. UNLOADING STORING AND HANDLING

Delivery: Hambro® joists will arrive in full tractor trailer loads banded in nested bundles. Suitableaccess must be provided so that trucks can move under their own power. Proper equipment must beprovided to unload the joists and Rollbars®.

Joist Identification: Hambro® Joists are tagged with an identification plate attached at one end onthe joist shoe.

Upon delivery, all materials must be cross-checked with the packing list by the buyer and/or erector atthe jobsite. All discrepancies and damages must be promptly reported to seller within 48 hours ofdelivery, otherwise replacement joists will be an additional charge

Storing: The Hambro® joists must be stored upright on a flat surface, and joists should be stackedcarefully to prevent damage. Care shall be exercised at all times to avoid damage through carelesshandling during unloading, storing, and erecting. Time will be saved during the erection process if,while unloading the bundles, they are stacked in some organized fashion, either by mark or floor.

Hoisting: When hoisted by crane, the cables can be placed at each end or at third points of thejoists. Cables must be placed under the top chord and never attached to the web members.

Damaged joists, regardless of the reason, may impair the performance and safety of the system andmust be repaired or replaced prior to erection. DO NOT MAKE FIELD REPAIRS TO DAMAGEDHAMBRO® JOISTS WITHOUT WRITTEN APPROVAL FROM YOUR STRUCTURAL ENGINEER ANDCONSULTING WITH A QUALIFIED HAMBRO REPRESENTATIVE.

III. SETTING THE JOISTS

Typical Spacing: Hambro® joists are typically spaced 4'-1 1/4" on center (o.c.), but to start theerection procedure, space them at approximately 4' o.c. on the bearing provided. For the sake ofsimplicity, in this manual the standard spacing will be 4'-1 1/4". (U.L. Designs also permit 5' and 6'joist spacing.)

Four points where extra care should be taken:

1. Direction of Top Chord: It is an absolute necessity that all top chords face the SAME DIRECTIONwithin a bay. This is confirmed by joist tag end directions shown on the Shop Drawings. The tagend of the joist will have a small stamped steel tag with the joist mark on it.

As you will note from Diagram #1, forms butt on one side of the top chord, but tuck under on theopposite side. If the joists are not installed as indicated, forms will not fit properly i.e. the forms willbe too wide or too narrow to suit the joist spacing.

DIAGRAM #1

2. Special joists (ie deep shoes, point loads or Hangerplate) will determine the direction of the topchord. The direction of the tag ends and top chords is shown on the shop drawing. Before youstart the installation determine the proper direction of the top chords and tag ends from the shopdrawings. A little care at the start will eliminate additional costs of removing Rollbars® andresetting joists.

3. End Joists: A close measurement should be taken for the first joist that is set, usually the one nextto the wall, beam, or tie joist. Careful measurement of this spacing, which is usually a little largeror smaller than the standard 4' spacing, will save unnecessary excessive shifting of the system afterall of the joists are set and Rollbars® are in place. All measurements should be taken from theslots of joist top chords.

4. Bearing: It is important to make sure that the joist shoes are placed properly on the supportingwalls or beams. Joists should be centered between walls or beams so that you get equal bearingfor both shoes. Follow the minimum dimensions specified on the approved shop drawing. Unlessnoted otherwise, the minimum bearing on masonry and wood support is 3 1/2”, and 2 1/2” onstructural steel. REDUCED BEARING COULD PRESENT A SAFETY HAZARD. As soon as theHambro joist is installed the Rollbar® shall be installed.

5. Long Joists: Particular attention should be paid to the erection of long Hambro® joists. Joists shallbe adequately braced using Rollbars® immediately after setting to prevent lateral movement. Thejoist must be straight (no sweep) and plumb before placing the concrete.

Important: As soon as the joists are erected, the Rollbars® should be installed.

Welding joist shoes may sometimes be required when bearing on a steel frame, only to restrain theframe. Hambro® itself typically does not require welding.

IV. INSTALLING THE ROLLBARS®

Slots in the top chord are 5/8" x 1 3/4" and spaced 7" o.c. The first Rollbars® at the end of the joist,nearest the beam or wall, must be installed with the clip angles on the Rollbars® facing the wall orbeam. It can only be removed by rotating the handles away from the wall and the clip anglespivoting away from the bottom of the plywood form.

ROLLBARS®: Note the various types and their specific purpose. Rollbars® are delivered f.o.b. thejobsite by Supplier for your use. Upon completion of any divisible portion of Hambro® work, Rollbars®

will be loaded onto Supplier's truck by Purchaser or equal.Standard Rollbar (SRB) is used fortypical 4’-1 1/4” joist to joist, joist toFlangehanger spacing. Alsoavailable in 5’ and 6’ lengths.

HANDLE

STANDARD ROLLBAR⟩ - SRB

LONG TAIL

"SAW CUT"

CLIP ANGLE

SHORT TAIL

Extension Rollbar (ERB) is adjustablefor joist to joist, and joist toFlangehanger spacing. Small ERBfrom 1’-10 3/4” to 3’-1”. Large ERB from3’-1” to 4’-7”.

EXTENSION ROLLBAR⟩ - TRB2 OR TRB3

Telescopic Rollbar (TRB) has a shorttail on one end and a flat arrow tip onthe other end for joist to ledger spacesonly.

TELESCOPIC ROLLBAR⟩ - TRB1

ARROW TIP

Flangehanger is a 13 gauge angle shipped in 20' lengths. Flangehanger is an optional accessorythat is provided only when specifically ordered. It has slots in the vertical leg which correspond to theslots in the Hambro® joist top chord. Flangehanger is field cut to length for attachment to steelbeams which are parallel to the joists. It can be welded or power shot to the flange of parallelbeams. Once the Flangehanger has been securely attached, the Rollbars® can be supported by thebeams. NOTE: Flangehanger is attach only to beams which are parallel to the Hambro® Joists andremains permanently attached to the beam.

POST

LEDGER

TRB1

DIAGRAM #3 DIAGRAM #4

Spacing: The Hambro® joist top chord has pre-punched holes every 7". In order to support formsproperly, care should be taken to install the Rollbars® at 21" o.c. (every third hole), for the usual 2 1/2"to 3 1/2" slab, but never greater than 28" o.c. Exceeding this dimension would be dangerous, since itoverloads the bars and plywood. IMPROPER SPACING OF ROLLBARS® MAY AFFECT THESTRUCTURAL SAFETY OF THE SYSTEM DURING THE CONCRETING STAGE. There should be aRollbar® 7" from the end of each plywood form.

Thickened Slabs: In the areas where thicker concrete slabs are specified, Rollbars® should beplaced at closer intervals. Where certain areas have been thickened and "Hangerplate™" is used,Rollbars® should not be spaced more than 14" o.c. for 6" slabs and 7" o.c. for slabs up to 8" thick.

Stagger Rollbar® spacing from bay to bay whenever possible to avoid having two Rollbar® ends in thesame slot. This will simplify the stripping procedure. This does not apply to the temporary bottomchord bracing or the first Rollbar® nearest the supporting beam or wall.

Sequence of Installation: Standard Rollbars® should be installed first, starting with the ends of thefirst two joists in the bay, and working toward the middle of the bay. Install the Telescopic Rollbars®

last.

Temporary Bottom Chord Bracing: To provide additional stability during concreting, Rollbars® shallbe inserted in the clips that are welded to the bottom chords of the joists as shown in Diagram #5.This temporary bracing is removed when stripping the forms as it is not required at the compositestage. At the end of each joist run, bottom chord bracing must be firmly braced to stable walls, orbeams or main structural frame and be firmly attached at both ends.

DIAGRAM #5

CAUTION:To prevent lateral movement of the top chords during construction, the lateral support provided byregular 4'-1 1/4" slotted Rollbars® must be carried on right through to the end walls or beams. WhereTRB's have been used between joists (odd spacing), positive spreaders must be spaced at 1/4 points(i.e., a 2" x4" cut to exact length). Note: Plywood forms ripped to the exact width will help providethe required lateral support.

Note: For smaller than "standard bays" but greater than 2'-8", you should use the TelescopicRollbars® supplied to support the forms. Caution: Telescopic Rollbars® should never be placed on topof a wall or beam as the form will be at the wrong elevation and encroach into the slab thickness inthat area. Telescopic Rollbars® should always be placed on ledger strips. On steel frame projects,Flangehanger placed on top of the beam flange proves to be a time saver. Only Extension andStandard Rollbars® can be used with Flangehanger.

Note: For joist spacing up to1'-9 3/4” and less, #4 rebar shouldbe used to support form(supplied by installer).

LEDGER

#4 REBAR@21" O.C.

(MAX)

1'-9 3/4" MAX.

FORM

DIAGRAM #6

IMPORTANT NOTICE:The Rollbars® shipped to the site are either new or used, but have been inspected and banded bysupplier. During the course of the project, the Rollbars® may be bent. All workmen should beinformed of the importance of a proper and improper bow in the Rollbars®. PROPER BOW: If youplace the ends of a Rollbar® on your fingers, the angle clips will rotate upward. If this were in a joist,the clips would rotate upward and be stopped by the plywood. The bow should not exceed 1".IMPROPER BOW: If you place the ends of the Rollbars® on your fingers, the angle clips would rotate

downward. In the construction stage, this would place the Rollbar® on its side. In this position, it hasvirtually no capacity to support the construction loads and is an unsafe condition.

V. PLACING THE REMOVABLE PLYWOOD FORMS

Plywood Type: The standard spacing (4'-1 1/4") is designed to accept a standard 4' x 8' sheet of CDX3/8" or 1/2" plywood. For garden apartment or townhouse applications, consider reusing 1/2" forms asroof sheathing. When using 3/8" plywood, the forms are to be overlapped at least 12". When using1/2" plywood, all joints should be butted since the thickness would encroach into the area of the topchord that is designed to be imbedded into the concrete (see Diagram #3). When the choice isavailable, you will find it more economical to use 3/8" plywood and "lap the joints".

End Bay Condition: When placing the plywood forms next to the end joists, be sure to avoid havingthe plywood sit on the bearing wall or beam. You will find that a plywood form bonded between theconcrete pour and the bearing wall or beam, is no longer removable and has to be chopped out.

In order to take advantage of the systems flexibility, it is recommended that the builder and othersubcontractors check the position of the joists in relation to any risers or slab openings, etc., whichwill be coming through the deck prior to placing the forms in the end bays. At this point, before theend bays are formed, in most cases, the entire deck can be shifted a few inches in either direction.Check and adjust joist bearing if necessary.

Oiling plywood is not required, however, it will save labor in stripping and will prolong the useful lifeof the forms. Forms are ordinarily stripped the day following the pour, provided the concrete strengthhas reached 500 psi. Do not oil the joists or mesh.

Slab Penetrations are achieved by attaching the desired size sleeve directly to the plywood. Foamblocks or short lengths of pipe are commonly used. After the slab is poured, the forms are removedwith the plywood. Openings greater than 8"x8" require double mesh and possibly rebar. Openingsshould not be closer than 6" to the joist top chord so as not to interfere with the composite action.

CAUTION:1. Bundles of plywood, mesh or Rollbars® should be placed on supporting walls or beams, never on

the joist system. The system is not designed for this condition and will present a serious safetyhazard, along with damage to the joists.

2. Before any load is imposed on joists and prior to the plywood forms being installed, there shouldbe at least four joists bays completed with standard Rollbars® including the temporary bottomchord bracing installed to safely develop the structural non-composite capacity of the Hambro®

joists.

3. Full sheets of plywood are recommended. When shorter pieces are used, make sure they areadequately lapped and supported and safe for workers and construction loads.

DIAGRAM #7

VII. PLACING THE CONCRETE

Concrete Mix: The minimum concrete compressive strength is 3,000 psi. The aggregate in theconcrete mix should not be greater than 3/4".

Screeding: When screeding, maintain a minimum depth of 1" above the top chord for a nominal 21/2" slab. You will notice that the joists are fabricated with a positive camber to offset the deflectioncaused by the weight of the concrete. It will come out as the slab is poured, leaving a small residualcamber for the remaining design load.

Slump: Field experience indicates that a 3 1/2" to 4 1/2" slump is easy to work with and finish.Greater slumps will create excessive leakage and costly clean-up.

CAUTION:Too high a slump reduces the strength of the concrete and causes excessive shrinkage cracks.Curing procedures should be in accordance with the latest ACI requirements.

Vibrating: The concrete is to be lightly but thoroughly vibrated to ensure:

1. The full encasement of the top chord in the concrete (letting the vibrator hit the top chord willassure encasement). This is very important to obtain the full design capacity of the system.

2. Elimination of "honeycombs".

3. The concrete is vibrated under the mesh. (i.e., Lay vibrator on deck and you will notice the meshbeing lifted as concrete flows under).

Construction Joints: When pouring and finishing a deck, it is not necessary to complete the entiredeck monolithically. If it becomes necessary to stop the pour parallel to the joists, the joint should bemidway between the joists, but never closer than 6" to the top chord. The mesh must extend at least12" beyond the break. If you stop a pour perpendicular to the joists, locate the joint over thesupporting walls or beam.

Flat sheets of welded wire mesh are recommended in lieu of rolled mesh for its ease of handling,and because it lays more naturally without the ends sticking up. The flat sheets are laid across thejoists with the long dimension running from joist to joist.

Lapping: Be sure to get the minimum lap of 6" perpendicular to joists and 12" lap parallel to joists.Be sure the mesh extends onto the perimeter beams or walls at least 4" in order to develop thecapacity of the slab.

Unless otherwise noted on the, a single layer of mesh is all that is typically required.

Always check the final construction documents or approved erection drawing for the properreinforcement and mesh type and follow the construction drawings for the placement of slabreinforcement.

The flat sheets of mesh should drape naturally as shown in Diagram #7. Do not step down the meshon either side of the top chord.

SAFETY PRECAUTIONS WHEN POURING CONCRETE:

Several simple precautions must be followed before and during the concrete pour to ensure a safeoperation:

1. Direct a man below during the pour to check that all Rollbars® remain in proper position during thepour.

2. As previously mentioned, Rollbar® spacing should be reduced if slabs thicker than 3 1/2" are to bepoured, or joist spacing exceeds 4'-1 1/4".

3. Check that plywood forms are properly lapped or butted, and that they have not moved sidewaysinto the top chord.

4. During the pour, care should be taken not to subject the joists to excessive construction loads orthe performance and safety of the system may be impaired. Do not pour concrete in excess ofslab thickness specified on drawings, and do not drop large bucket loads or pump excessiveconcrete in a concentrated area.

5. The pre-punched holes in the top chord section and the Rollbars® are not designed to supportbuggies; therefore, runways must be placed across the top chord. This is usually accomplishedwith wood planks, laid perpendicular to the joists.

6. CAUTION...Do not overload the slab or joists at any phase of construction.

VIII. STRIPPING THE FORMS

At such time as the concrete reaches a cylinder strength of 500 psi, the Rollbars® and plywood formscan be stripped and the concrete deck is now ready for work.

Avoid dropping Rollbars® on slab, as this may cause chipping of the concrete surface. Avoiddropping the plywood forms when stripping. This causes damage to corners and edges and reducesthe amount of re-use.

After stripping, Rollbars® should be neatly stacked parallel to each other on a pallet beforetransporting.

IX. IMPORTANT NOTICES

A. Care should be exercised not to overload the system; pallets of block and bundles of mesh,plywood or gypboard should be placed over supporting walls or beams or spread out whenplaced on the slab.

B. DO NOT MODIFY OR ALTER ANY HAMBRO® PRODUCT WITHOUT FIRST OBTAININGWRITTEN APPROVAL FOR THE DESIRED CHANGE FROM THE STRUCTURAL ENGINEER,AND GUIDANCE FROM A QUALIFIED HAMBRO® REPRESENTATIVE.

C. Similarly, if it becomes necessary to deviate from the Approved Shop Drawings supplied witheach job, obtain approval of the structural engineer prior to making that change.

D. When core drilling a slab, avoid drilling within 6" of a joist. Openings 8" x 8" or larger requiredouble mesh and possibly rebar. Consult the structural engineer.

-8-E. In the event a joist is damaged, by whatever cause, obtain written approval from the project

structural engineer before it is used.F. In hot, sunny weather, it is good practice to wet down the deck with water to prevent theconcrete from setting too rapidly, which may cause excessive shrinkage cracks to appear.Always following ACI requirements.

X. WINTER CONSTRUCTION

The Hambro® D-500 Composite Floor System was designed in Canada and is extensively constructedyear round. The winters in Canada are long and cold with as much as 140" of snow, andtemperatures down to -30o Fahrenheit. Folllow the instructions provided by the structural engineerand the ACI recommmended practice for cold weather concrete.

A. Concrete: Non-chloride admixtures, if required.

B. Testing: In addition to normal lab curing of concrete cylinders, an additional set of cylindersis left on the site under the slab which has been poured, for checking of site curingconditions.

C. Site Preparation:

1. Temporary Heat As a general rule, heaters are placed under the floor to be poured. Theidea is to get the temperature on the top of the form to about 50o to 60o F., whichcorresponds to a room temperature of 70o to 80o underneath the slab. Before the heatersare started, all window openings in the floor below are closed in with tarpaulins.

2. Wind Breaks At low temperatures, wind has a high chill factor and when this prevails, a 2'to 4' high wind break is installed on the windward side.

XI. CORRECTIVE REMEDIES IN THE FIELD

There are certain conditions that, in some instances, appear and are not to be considered"manufacturing defects". Because of Hambro's® simplicity, they are corrected in the field as astandard procedure by the installer:

A. Joist Sweep: Occasionally, some Hambro® joists may exhibit excessive sweep. This conditionis easily corrected as a standard procedure of the installer at the job site. In the few instanceswhere necessary, simply lay the joist on its side, supported at each end. The weight of one ortwo workmen standing on the joist will usually correct this sweep. Minimal sweep is nothing tobe concerned with, as long as there are relatively straight joists at the beginning of theinstallation. The continued application of Rollbars® will then further straighten successivejoists that may have minimal sweep.

B. Bent Shoes: Bent shoes which are no longer 90o to the plane of the web are corrected bysimply hammering them level or by merely shimming the out of level areas so as to plumb thejoist and obtain adequate bearing. The grout in the concrete mix will readily run under theshimmed shoes.

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Hambro® Gives You Every Advantagen n OPEN WEB JOIST CONFIGURATION, NO n n VERY WELL SUITED FOR WOOD,BRIDGING, AND 4' JOIST SPACING STEEL STUD, STEEL, AND CONCRETEaccommodates mechanical distribution FRAMES.within the joist plenum; permits full n n U.L. DESIGNS FOR 1, 2, AND 3 HOURSlengths of duct and water pipe, reducing with gypsum board, spray fire-proofingorthe many connections when using shorter acoustical tile. One layer of fire codelengths. Virtually eliminates dropped gypsum screw attached to furring channelsceilings and soffit enclosures. spaced 2' o.c. provide up to 3 hours ofn n REDUCES BUILDING HEIGHT and protection. For up to 1-1/2 hours, U.L. designsdevelops savings in the cost of skins designs permit UNPROTECTED CEILINGand all other vertical components. PENETRATIONS of up to 196 sq. in. pern n SHALLOWER JOISTS WITH RIGIDITY 100 sq. ft. of ceiling area (2 hours permitsAND STIFFNESS; HAMBRO® composite 100 sq. ft.)... eliminating fire dampersdesign generally saves 2 to 4 inches or protection at ceiling openings.against conventional joist systems. n n STC 57 ON BARE CONCRETE.Hambro® slabs key into voids in block n n SLAB PENETRATIONS ARE EASYand encase top flange of interior beams, using either sleeves, styrofoam or wooddevelops diaphragm action and ties the blocking prior to concreting. No metalstructure together. decking to cut or tendons to be concerned

with, fewer joists offers flexibility. Slender 3,000 psi slab makes coring simpler, if necessary.

ApprovalsThe Hambro® D-500 Composite Floor System has been approved, listed, classified, recognized,certified, and/or accepted by the following leading national and local building codes andauthorities:

n (B.O.C.A. No. 78-99) Building Officials Code Administratorsn Underwriters Laboratories, Inc. designs for 1, 2, and 3 hour fire ratings.n HUD-FHA Material Release 810cn City of Baltimore, Philadelphia, Wash. D.C., Fairfax County, Richmond, Wilmington, Los Angeles, Seattle, etc.n New York City Approval BSA 360-74 SM. & BSA 618-74 SMn International Conference of Building Officials No. PFC 2869n Southern Building Code Congress International Report No. 7395-77n Metropolitan Dade County Building Code No. 77-189.5n CMHC No. 6292R, ULC, NRC, etc., Canadan Institut Fur Bautechnik, Zulassung, No. Z-26., West Germanyn CSTB Technical Notice No. 3/88-189, Francen Agreement Board Certificate No. 74/255, United Kingdomn Canadian Pat. No. 874180n U.S. Pat. No. 3818083, 3819143, 8341597, 3845594, 3913296, 3945168, 3979868, 4015396, 4584815, 4729201n Foreign Patents Around The World

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